Overview

Ordestro is a modular ERP platform built for industrial manufacturers, while Defectopia is a CV-powered visual quality control system. Together, they deliver end-to-end digital transformation for smart factories.

Our Contribution

A7 developed and deployed the ERP platform with real-time factory visibility and integrated quality control:

• Developed modules for inventory, procurement, production, and workforce management
• Built Defectopia, a computer vision system for detecting material defects in real time
• Integrated machine vision with factory dashboards and alert systems
• Enabled predictive maintenance, QA logging, and defect analytics

Results

• Reduced defect-related downtime by 30%
• Increased QA efficiency with real-time feedback loops
• Enabled data-driven production optimization

Steps to realize project

• Discovery and Factory Process Analysis

We began by immersing ourselves in the client’s manufacturing workflows. Our team conducted on-site audits, interviewed floor managers, and reviewed existing digital infrastructure. This allowed us to identify bottlenecks, inefficiencies, and opportunities for automation and quality control using AI and data integration.

• Design of Modular ERP Architecture

Based on the analysis, we designed a flexible ERP system tailored to the client's operations — including inventory, production planning, quality assurance, and reporting modules. Each module was developed independently to allow scaling and customization in the future.

• Implementation of CV Models and Training Pipelines

We built and trained computer vision models to detect defects in raw materials (e.g. logs, pipes, surfaces). Custom training pipelines were developed to retrain models with new datasets and continuously improve accuracy. Detection occurred in real time on the production line.

• Integration with Edge Devices and Control Systems

To achieve low-latency detection and ensure minimal disruption, our CV system was deployed on local edge devices connected directly to industrial cameras. We also integrated with PLCs and MES systems to trigger alerts and automate responses to critical defects.

• Deployment of Dashboards and Defect Alerting Tools

We delivered intuitive dashboards for operators and managers to monitor production quality, review defect patterns, and export reports. Real-time alerting systems notified teams when anomalies were detected, enabling faster reaction and minimizing waste.

• Support, Retraining Models, and System Scaling

Post-deployment, we continued to support the system by monitoring its performance, retraining CV models with fresh data, and rolling out the ERP to additional factory lines. As the client scaled production, our architecture allowed them to replicate the system with minimal setup.

“With A7's expertise, we transformed our entire production line. Their computer vision system helped us catch defects we never saw before, and the ERP made our operations more efficient and transparent. The platform paid for itself within months — both in cost savings and improved quality. The team was responsive, technically sharp, and deeply understood the needs of our industry.”